Yamaha F9.9J, FT9.9L User Manual

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Page 1

OWNER’S MANUAL

Read this manual carefully before operating this

outboard motor.

F9.9J FT9.9L

6DR-28199-71-E0

Page 2

Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.

Page 3

Important manual information

WARNING

NOTICE

TIP:

EMU25108

To the owner

Thank you for selecting a Yamaha outboard motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important information is distinguished in the following ways.

: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

EWM00782

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

ECM00702

A NOTICE indicates special precautions that must be taken to avoid damage to the outboard motor or other property.

between your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer. To ensure long product life, Yamaha recommends that you use the product and perform the specified periodic inspections and maintenance by correctly following the instructions in the owner’s manual. Any damage resulting from neglect of these instructions is not covered by warranty. Some countries have laws or regulations restricting users from taking the product out of the country where it was purchased, and it may be impossible to register the product in the destination country. Additionally, the warranty may not apply in certain regions. When planning to take the product to another country, consult the dealer where the product was purchased for further information. If the product was purchased used, please consult your closest dealer for customer reregistration, and to be eligible for the specified services.

The F9.9JMH, F9.9JE, FT9.9LMH, FT9.9LE, FT9.9LEP and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model.

EMU25122

A TIP provides key information to make procedures easier or clearer.

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies

F9.9J, FT9.9L

OWNER’S MANUAL

1st Edition, October 2013

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

Page 4

Safety information ............................. 1

Outboard motor safety .................... 1

Propeller............................................. 1

Rotating parts..................................... 1

Hot parts ............................................ 1

Electric shock..................................... 1

Power tilt ............................................ 1

Engine shut-off cord (lanyard)............ 1

Gasoline ............................................. 1

Gasoline exposure and spills ............. 2

Carbon monoxide .............................. 2

Modifications...................................... 2

Boating safety ................................. 2

Alcohol and drugs.............................. 2

Personal flotation devices (PFDs) ...... 2

People in the water ............................ 2

Passengers......................................... 2

Overloading........................................ 2

Avoid collisions .................................. 3

Weather.............................................. 3

Passenger training ............................. 3

Boating safety publications................ 3

Laws and regulations......................... 3

General information .......................... 4

Identification numbers record ......... 4

Outboard motor serial number........... 4

Key number........................................ 4

EC Declaration of Conformity

(DoC) ........................................... 4

CE Marking .................................... 5

Read manuals and labels ................ 6

Warning labels ................................... 6

Specifications and requirements... 10

Specifications................................ 10

Installation requirements............... 12

Boat horsepower rating.................... 12

Mounting outboard motor................ 12

Remote control requirements ....... 12

Battery requirements..................... 13

Battery specifications....................... 13

Mounting battery.............................. 13

Without a rectifier or Rectifier

Regulator ...................................... 13

Propeller selection ........................ 13

Start-in-gear protection ................ 14

Engine oil requirements ................ 14

Fuel requirements ......................... 15

Gasoline ........................................... 15

Anti-fouling paint .......................... 15

Outboard motor disposal

requirements.............................. 15

Emergency equipment.................. 15

Components .................................... 17

Components diagram ................... 17

Fuel tank........................................... 19

Fuel joint........................................... 20

Fuel gauge........................................ 20

Fuel tank cap.................................... 20

Air vent screw................................... 20

Remote control box.......................... 20

Remote control lever........................ 20

Neutral interlock trigger.................... 21

Neutral throttle lever......................... 21

Choke switch.................................... 21

Tiller handle ..................................... 21

Gear shift lever ................................ 21

Throttle grip ..................................... 22

Throttle indicator ............................. 22

Throttle friction adjuster ................... 22

Engine shut-off cord (lanyard) and

clip ................................................ 23

Engine stop button .......................... 23

Choke knob for pull type.................. 24

Manual starter handle....................... 24

Main switch ...................................... 24

Power tilt switch............................... 24

Steering friction adjuster .................. 25

Trim rod (tilt pin) ............................... 25

Tilt lock mechanism ......................... 26

Tilt support knob .............................. 26

Tilt support bar................................. 26

Power tilt unit ................................... 26

Cowling lock lever ............................ 27

Flushing device ................................ 27

Page 5

Table of contents

Alert indicator .................................. 27

Instruments and indicators ............28

Indicators ..................................... 28

Low oil pressure-alert indicator........ 28

Engine control system .................... 29

Alert system .................................. 29

Low oil pressure alert....................... 29

Installation ....................................... 30

Installation ..................................... 30

Mounting the outboard motor.......... 30

Clamping the outboard motor.......... 32

Operation ......................................... 33

First-time operation....................... 33

Fill engine oil .................................... 33

Breaking in engine............................ 33

Getting to know your boat ............... 33

Checks before starting engine ...... 33

Fuel level .......................................... 34

Removing top cowling ..................... 34

Fuel system...................................... 34

Controls............................................ 34

Engine shut-off cord (lanyard).......... 34

Engine oil.......................................... 35

Outboard motor ............................... 35

Flushing device ................................ 35

Install top cowling ............................ 36

Checking power tilt system.............. 36

Battery.............................................. 37

Filling fuel ..................................... 37

Operating engine........................... 38

Sending fuel (portable tank) ............. 38

Starting engine................................. 39

Checks after starting engine ......... 43

Cooling water ................................... 43

Warming up engine ....................... 44

Manual start and electric start

models .......................................... 44

Checks after engine warm up ....... 44

Shifting ............................................. 44

Stop switches................................... 44

Shifting.......................................... 44

Stopping boat ............................... 46

Stopping engine............................ 46

Procedure......................................... 46

Procedure......................................... 47

Trimming outboard motor............. 47

Adjusting trim angle for manual tilt

models .......................................... 48

Adjusting trim angle (power tilt

models) ......................................... 48

Adjusting boat trim........................... 49

Tilting up and down ...................... 50

Procedure for tilting up (manual tilt

models) ......................................... 50

Procedure for tilting up (power tilt

models) ......................................... 51

Procedure for tilting down (manual

tilt models) .................................... 52

Procedure for tilting down (power tilt

models) ......................................... 52

Shallow water .............................. 52

Cruising in shallow water (manual tilt

models) ......................................... 52

Power tilt models.............................. 54

Cruising in other conditions.......... 54

Maintenance.................................... 55

Transporting and storing outboard

motor ......................................... 55

Dismounting the outboard motor..... 55

Storing outboard motor.................... 57

Procedure......................................... 57

Lubrication ....................................... 58

Flushing power unit.......................... 59

Cleaning the outboard motor ........... 59

Checking painted surface of

outboard motor............................. 60

Periodic maintenance ................... 60

Replacement parts........................... 60

Severe operating conditions ............ 60

Maintenance chart 1......................... 61

Maintenance chart 2......................... 63

Greasing ........................................... 64

Page 6

Table of contents

Cleaning and adjusting spark plug... 65

Checking fuel filter ........................... 66

Inspecting idle speed....................... 66

Changing engine oil.......................... 66

Inspecting wiring and connectors.... 68

Checking propeller........................... 68

Removing propeller.......................... 69

Installing propeller............................ 70

Changing gear oil ............................. 70

Cleaning fuel tank ............................ 72

Inspecting and replacing anode(s) ... 73 Checking battery (for electric start

models) ......................................... 73

Connecting the battery..................... 74

Disconnecting the battery ................ 74

Trouble Recovery ............................ 75

Troubleshooting ............................ 75

Temporary action in emergency ... 78

Impact damage ................................ 78

Replacing fuse ................................. 78

Power tilt will not operate................. 79

Starter will not operate..................... 79

Emergency starting engine .............. 80

Engine fails to operate .................. 81

Emergency engine operation ........... 81

Treatment of submerged motor .... 81

INDEX ............................................... 82

Page 7

Safety information

EMU33623

Outboard motor safety

Observe these precautions at all times.

EMU36502

Propeller

People can be injured or killed if they come in contact with the propeller. The propeller can keep moving even when the motor is in neutral, and sharp edges of the propeller can cut even when stationary.  Stop the engine when a person is in the

water near you.

 Keep people out of reach of the propeller,

even when the engine is off.

EMU40272

Rotating parts

Hands, feet, hair, jewelry, clothing, personal flotation device (PFD) straps, etc., can become entangled with internal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in place whenever possible. Do not remove or replace the top cowling with the engine running. Only operate the engine with the top cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, PFD straps, etc., away from any exposed moving parts.

EMU33641

Hot parts

During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the engine has cooled.

EMU33651

Electric shock

Do not touch any electrical parts while starting or operating the engine. They can cause shock or electrocution.

EMU34791

Power tilt

Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted. Keep body parts out of this area at all times. Be sure no one is in this area before operating the power tilt mechanism. The power tilt switches operate even when the main switch is off. Keep people be away from the switches whenever working around the motor. Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidentally falls.

EMU33672

Engine shut-off cord (lanyard)

Attach the engine shut-off cord so that the engine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving people stranded, or running over people or objects. Always attach the engine shut-off cord to a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the helm while the boat is moving. Do not attach the cord to clothing that could tear loose, or route the cord where it could become entangled, preventing it from functioning. Do not route the cord where it is likely to be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and objects forward.

EMU33811

Gasoline

Gasoline and its vapors are highly flammable and explosive. Always, refuel according

to the procedure on page 38 to reduce the risk of fire and explosion.

Page 8

Safety information

EMU33821

Gasoline exposure and spills

Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.

EMU33901

Carbon monoxide

This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.

EMU33781

Modifications

Do not attempt to modify this outboard motor. Modifications to your outboard motor may reduce safety and reliability, and render the outboard unsafe or illegal to use.

EMU33741

Boating safety

This section includes a few of the many important safety precautions that you should follow when boating.

EMU33711

Alcohol and drugs

Never operate after drinking alcohol or taking drugs. Intoxication is one of the most common factors contributing to boating fatalities.

EMU40281

Personal flotation devices (PFDs)

Have an approved PFD on board for every occupant. Yamaha recommends that you must wear a PFD whenever boating. At a minimum, children and non-swimmers

should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating conditions.

EMU33732

People in the water

Always watch carefully for people in the water, such as swimmers, skiers, or divers, whenever the engine is running. When someone is in the water near the boat, shift into neutral and stop the engine. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Stop the engine when a person is in the water near you.

EMU33752

Passengers

Consult your boat manufacturer’s instructions for details about appropriate passenger locations in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle speed. Standing or sitting in non-designated locations may result in being thrown either overboard or within the boat due to waves, wakes, or sudden changes in speed or direction. Even when people are positioned properly, alert your passengers if you must make any unusual maneuver. Always avoid jumping waves or wakes.

EMU33762

Overloading

Do not overload the boat. Consult the boat capacity plate or boat manufacturer for maximum weight and number of passengers. Be sure that weight is properly distributed according to the boat manufacturer’s instructions. Overloading or incorrect weight distribution can compromise the boats handling and lead to an accident, capsizing or swamping.

Page 9

Safety information

ZMU06025

EMU33773

Avoid collisions

Scan constantly for people, objects, and other boats. Be alert for conditions that limit your visibility or block your vision of others.

Operate defensively at safe speeds and keep a safe distance away from people, objects, and other boats.  Do not follow directly behind other boats or

waterskiers.

 Avoid sharp turns or other maneuvers that

make it hard for others to avoid you or understand where you are going.

 Avoid areas with submerged objects or

shallow water.

 Ride within your limits and avoid aggres-

sive maneuvers to reduce the risk of loss of control, ejection, and collision.

 Take early action to avoid collisions. Re-

member, boats do not have brakes, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in another direction.

EMU33791

Weather

Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.

EMU33881

Passenger training

Make sure at least one other passenger is trained to operate the boat in the event of an emergency.

EMU33891

Boating safety publications

Be informed about boating safety. Additional publications and information can be obtained from many boating organizations.

EMU33601

Laws and regulations

Know the marine laws and regulations where you will be boating- and obey them. Several sets of rules prevail according to geographic location, but all are basically the same as the International Rules of the Road.

Page 10

General information

ZMU05335

ZMU05336

EMU25172

Identification numbers record

EMU25185

Outboard motor serial number

The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen.

1. Outboard motor serial number location

EMU25192

Key number

If a main key switch is equipped with the motor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.

1. Outboard motor serial number location

1. Key number

EMU37292

EC Declaration of Conformity

(DoC)

This outboard motor conforms to certain portions of the European Parliament directive relating to machinery. Each conformed outboard motor accompanied with EC DoC.EC DoC contains the following information;

 Name of Engine Manufacture  Model name

Page 11

 Product code of model (Approved model

ZMU05336

ZMU06040

code)

 Code of conformed directives

EMU25207

CE Marking

Outboard motors affixed with this “CE”marking conform with the directives of; 2006/42/EC, 94/25/EC - 2003/44/EC and 2004/108/EC.

1. CE marking location

General information

1. CE marking location

Page 12

General information

EMU33524

Read manuals and labels

Before operating or working on this outboard motor:

 Read this manual.  Read any manuals supplied with the boat.  Read all labels on the outboard motor and the boat.

If you need any additional information, contact your Yamaha dealer.

EMU33834

Warning labels

If these labels are damaged or missing, contact your Yamaha dealer for replacements.

F9.9JMH, FT9.9LMH

Page 13

F9.9JE, FT9.9LE, FT9.9LEP

General information

Page 14

General information

WARNING

ZMU05706

EMU33913

Contents of labels

The above warning labels mean as follows.

EWM01692

Emergency starting does not have startin-gear protection. Ensure shift control is in neutral before starting engine.

EWM01682

 Keep hands, hair, and clothing away

from rotating parts while the engine is running.

 Do not touch or remove electrical parts

when starting or during operation.

EWM01672

 Read Owner’s Manuals and labels.  Wear an approved personal flotation de-

vice (PFD).

 Attach engine shut-off cord (lanyard) to

your PFD, arm, or leg so the engine stops if you accidentally leave the helm, which could prevent a runaway boat.

Page 15

General information

ZMU05696

ZMU05664

ZMU05665

ZMU05666

ZMU05667

ZMU05668

EMU33844

Symbols

The following symbols mean as follows.

Notice/Warning

Read Owner’s Manual

Electrical hazard

Remote control lever/gear shift lever operating direction, dual direction

Engine start/ Engine cranking

Hazard caused by continuous rotation

Page 16

Specifications and requirements

TIP:

EMU34522

Specifications

“(AL)” stated in the specification data below represents the numerical value for the aluminum propeller installed. Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed.

EMU2821U

Dimension and weight:

Overall length:

F9.9JE 557 mm (21.9 in) F9.9JMH 983 mm (38.7 in) FT9.9LE 557 mm (21.9 in) FT9.9LEP 557 mm (21.9 in) FT9.9LMH 1043 mm (41.1 in)

Overall width:

F9.9JE 333 mm (13.1 in) F9.9JMH 357 mm (14.1 in) FT9.9LE 333 mm (13.1 in) FT9.9LEP 333 mm (13.1 in) FT9.9LMH 355 mm (14.0 in)

Overall height S:

F9.9JE 1008 mm (39.7 in) F9.9JMH 1008 mm (39.7 in)

Overall height L:

F9.9JE 1135 mm (44.7 in) F9.9JMH 1135 mm (44.7 in) FT9.9LE 1195 mm (47.0 in) FT9.9LEP 1195 mm (47.0 in) FT9.9LMH 1195 mm (47.0 in)

Overall height X:

FT9.9LE 1263 mm (49.7 in) FT9.9LMH 1263 mm (49.7 in)

Motor transom height S:

F9.9JE 431 mm (17.0 in) F9.9JMH 431 mm (17.0 in)

Motor transom height L:

F9.9JE 558 mm (22.0 in) F9.9JMH 558 mm (22.0 in) FT9.9LE 552 mm (21.7 in) FT9.9LEP 557 mm (21.9 in) FT9.9LMH 552 mm (21.7 in)

Motor transom height X:

FT9.9LE 620 mm (24.4 in) FT9.9LMH 620 mm (24.4 in)

Dry weight (AL) S:

F9.9JE 42 kg (93 lb) F9.9JMH 40 kg (88 lb)

Dry weight (AL) L:

F9.9JE 43 kg (95 lb) F9.9JMH 41 kg (90 lb) FT9.9LE 44 kg (97 lb) FT9.9LEP 49 kg (108 lb) FT9.9LMH 43 kg (95 lb)

Dry weight (AL) X:

FT9.9LE 45 kg (99 lb) FT9.9LMH 44 kg (97 lb)

Performance:

Full throttle operating range:

5000–6000 r/min

Rated power:

7.3 kW (9.9 HP)

Idle speed (in neutral):

1000–1100 r/min

Power unit:

Type:

4-stroke SOHC L2 4 valves

Total displacement:

212 cm³ (12.9 c.i.)

Bore × stroke:

56.0 × 43.0 mm (2.20 × 1.69 in)

Ignition system:

CDI

Spark plug (NGK):

BR6HS-10

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

Page 17

Specifications and requirements

Steering system:

F9.9JE Remote steering F9.9JMH Tiller handle FT9.9LE Remote steering FT9.9LEP Remote steering FT9.9LMH Tiller handle

Starting system:

F9.9JE Electric starter F9.9JMH Manual starter FT9.9LE Electric starter FT9.9LEP Electric starter FT9.9LMH Manual starter

Starting carburetion system:

Choke valve

Valve clearance IN (cold engine):

0.15–0.20 mm (0.0059–0.0079 in)

Valve clearance EX (cold engine):

0.20–0.25 mm (0.0079–0.0098 in)

Cold cranking amps (CCA/EN):

F9.9JE 347–411 A FT9.9LE 347–411 A FT9.9LEP 347–411 A

Min. rated capacity (20HR/IEC):

F9.9JE 40 Ah FT9.9LE 40 Ah FT9.9LEP 40 Ah

Maximum generator output:

6 A

Lower unit:

Gear shift positions:

Forward-neutral-reverse

Gear ratio:

F9.9JE 2.08(27/13) F9.9JMH 2.08(27/13) FT9.9LE 2.92(38/13) FT9.9LEP 2.92(38/13) FT9.9LMH 2.92(38/13)

Trim and tilt system:

F9.9JE Manual tilt F9.9JMH Manual tilt FT9.9LE Manual tilt FT9.9LEP Power tilt FT9.9LMH Manual tilt

Propeller mark:

F9.9JE N F9.9JMH N FT9.9LE R FT9.9LEP R FT9.9LMH R

Fuel and oil:

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

Fuel tank capacity:

12 L (3.17 US gal, 2.64 Imp.gal)

Recommended engine oil:

YAMALUBE 4 or 4-stroke outboard motor oil

Recommended engine oil grade 1:

SAE 10W-30/10W-40/5W-30 API SE/SF/SG/SH/SJ/SL

Engine oil quantity:

0.8 L (0.85 US qt, 0.70 Imp.qt)

Lubrication system:

Wet sump

Recommended gear oil:

YAMALUBE outboard gear oil or Hypoid gear oil

Recommended gear oil grade:

SAE 90 API GL-4

Page 18

Specifications and requirements

WARNING

Gear oil quantity:

F9.9JE 0.150 L (0.159 US qt,

0.132 Imp.qt) F9.9JMH 0.150 L (0.159 US qt,

0.132 Imp.qt) FT9.9LE 0.370 L (0.391 US qt,

0.326 Imp.qt) FT9.9LEP 0.370 L (0.391 US qt,

0.326 Imp.qt) FT9.9LMH 0.370 L (0.391 US qt,

0.326 Imp.qt)

Tightening torque:

Spark plug:

24 Nm (2.45 kgf-m, 17.7 ft-lb)

Propeller nut:

F9.9JE 17 Nm (1.73 kgf-m, 12.5 ft-lb) F9.9JMH 17 Nm (1.73 kgf-m, 12.5 ft-lb) FT9.9LE 21 Nm (2.14 kgf-m, 15.5 ft-lb) FT9.9LEP 21 Nm (2.14 kgf-m, 15.5 ft-lb) FT9.9LMH 21 Nm (2.14 kgf-m,

15.5 ft-lb)

Engine oil drain bolt:

24 Nm (2.45 kgf-m, 17.7 ft-lb)

Noise and vibration level:

Operator sound pressure level (ICOMIA 39/94):

78.2 dB(A)

Vibration on tiller handle (ICOMIA 38/94):

F9.9JMH Vibration on tiller handle is under 2.5 m/s² FT9.9LMH Vibration on tiller handle is under 2.5 m/s²

EMU33555

Installation requirements

EMU33565

Boat horsepower rating

EWM01561

Overpowering a boat can cause severe instability.

Before installing the outboard motor(s), confirm that the total horsepower of your outboard motor(s) does not exceed the boats maximum horsepower rating. See the boat’s capacity plate or contact the manufacturer.

EMU40491

Mounting outboard motor

EWM02501

 Improper mounting of the outboard mo-

tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards.

 Because the outboard motor is very

heavy, special equipment and training is required to mount it safely.

Your dealer or other person experienced in proper rigging should mount the outboard motor using correct equipment and complete rigging instructions. For further information, see page 30.

EMU33582

Remote control requirements

EWM01581

 If the engine starts in gear, the boat can

move suddenly and unexpectedly, possibly causing a collision or throwing passengers overboard.

 If the engine ever starts in gear, the

start-in-gear protection device is not working correctly and you should discontinue using the outboard. Contact your Yamaha dealer.

The remote control unit must be equipped with a start-in-gear protection device(s). This device prevents the engine from starting unless it is in neutral.

Page 19

Specifications and requirements

NOTICE

EMU25695

Battery requirements

EMU25723

Battery specifications

Cold cranking amps (CCA/EN):

F9.9JE 347–411 A FT9.9LE 347–411 A FT9.9LEP 347–411 A

Min. rated capacity (20HR/IEC):

F9.9JE 40 Ah FT9.9LE 40 Ah FT9.9LEP 40 Ah

The engine cannot be started if battery voltage is too low.

EMU36291

Mounting battery

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. WARNING! Do not put flammable

items, or loose heavy or metal objects in the same compartment as the battery. Fire, explosion or sparks could result.

[EWM01821]

EMU44770

Without a rectifier or Rectifier Regulator

ECM01091

A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator.

If you wish to use a battery with the models without a rectifier or Rectifier Regulator, install an optional Rectifier Regulator. Install an optional Rectifier Regulator or use accessories rated to withstand 18 volts or higher with the above models. Consult your Yamaha dealer for details on installing an optional Rectifier Regulator.

EMU34196

Propeller selection

Next to selecting an outboard motor, selecting the right propeller is one of the most important purchasing decisions a boater can make. The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures propellers for every Yamaha outboard motor and every application. Your outboard motor came with a Yamaha propeller selected to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate. Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boatload. Generally, select a larger pitch propeller for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, select the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads. To check the propeller, see page 68.

Page 20

Specifications and requirements

ZMU04606

123

ZMU04604

123

ZMU06854

122˚F

50˚C

104

SAE API

SE SF SG SH

-10

-4

-20

10W–30

10W–40

5W–30

ZMU06855

122˚F

50˚C

104

SAE API

-10

-4

-20

15W–40

20W–40

20W–50

Recommended engine oil:

YAMALUBE 4 or 4-stroke outboard motor oil

Recommended engine oil grade 1:

SAE 10W-30/10W-40/5W-30 API SE/SF/SG/SH/SJ/SL

Recommended engine oil grade 2:

SAE 15W-40/20W-40/20W-50 API SH/SJ/SL

Engine oil quantity:

0.8 L (0.85 US qt, 0.70 Imp.qt)

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

EMU25771

Start-in-gear protection

Yamaha outboard motors or Yamaha-approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Always select neutral before starting the engine.

EMU39693

Engine oil requirements

Select an oil grade according to the average temperatures in the area where the outboard motor will be used.

If oil grades listed under Recommended engine oil grade 1 are not available, select an alternative oil grade listed under Recommended engine oil grade 2.

Recommended engine oil grade 1

Recommended engine oil grade 2

Page 21

Specifications and requirements

NOTICE

EMU36361

Fuel requirements

EMU40202

Gasoline

Use a good quality gasoline that meets the minimum octane rating. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

ECM01982

 Do not use leaded gasoline. Leaded

gasoline can seriously damage the engine.

 Avoid getting water and contaminants in

the fuel tank. Contaminated fuel can cause poor performance or engine damage. Use only fresh gasoline that has been stored in clean containers.

Gasohol

There are two types of gasohol: gasohol containing ethanol (E10) and that containing methanol. Ethanol can be used if the ethanol content does not exceed 10% and the fuel meets the minimum octane ratings. E85 is a fuel containing 85% ethanol and must not be used in your outboard motor. All ethanol blends containing more than 10% ethanol can cause fuel system damage or cause engine starting and running problems. Yamaha does not recommend gasohol containing methanol because it can cause fuel system damage or engine performance problems. It is recommended that you install a waterseparating marine fuel filter assembly (10 micron minimum) between your boat’s fuel tank and outboard motor when using ethanol. Ethanol is known to allow moisture to be ab-

sorbed into boat fuel tanks and systems. Moisture in the fuel can cause corrosion of metallic fuel system components, starting and running complaints and require additional fuel system maintenance.

EMU36331

Anti-fouling paint

A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.

EMU40302

Outboard motor disposal re-

quirements

Never illegally discard (dump) the outboard motor. Yamaha recommends consulting the dealer about discarding the outboard motor.

EMU36353

Emergency equipment

Keep the following items onboard in case there is trouble with the outboard motor.  A tool kit with assorted screwdrivers, pliers,

wrenches (including metric sizes), and electrical tape.

 Waterproof flashlight with extra batteries.  An extra engine shut-off cord (lanyard) with

clip.

Page 22

Specifications and requirements

 Spare parts, such as an extra set of spark

plugs.

Consult your Yamaha dealer for details.

Page 23

Components

TIP:

ZMU07901

EMU2579Z

Components diagram

* May not be exactly as shown; also may not be included as standard equipment on all models (order from dealer).

F9.9JMH, F9.9JE

1. Top cowling

2. Clamp bracket

3. Trim rod

4. Drain screw

5. Cooling water inlet

6. Propeller

7. Cowling lock lever

8. Idle hole

9. Anti-cavitation plate

10.Remote control box (side mount type)*

11.Fuel tank

Page 24

Components

ZMU07902

FT9.9LMH, FT9.9LE, FT9.9LEP

1. Top cowling

2. Clamp bracket

3. Trim rod*

4. Drain screw

5. Cooling water inlet

6. Propeller

7. Cowling lock lever

8. Idle hole

9. Anti-cavitation plate

10.Remote control box (side mount type)*

11.Fuel tank

Page 25

Components

WARNING

10 12 11 13

3 4

10 11 12

148

ZMU07903

1. Manual starter handle*

2. Choke knob*

3. Flushing device

4. Steering friction adjuster*

5. Tilt lock lever*

6. Tilt support knob*

7. Restraint cable attachment

8. Clamp screw

9. Alert indicator

10.Engine stop button*

11.Gear shift lever*

12.Throttle friction adjuster*

13.Throttle grip*

14.Engine shut-off cord (lanyard)

EMU25804

Fuel tank

If your model was equipped with a portable fuel tank, its function is as follows.

EWM00021

The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Commercial users should conform to relevant licensing or approval authority regulations.

Page 26

Components

ZMU01992

1. Air vent screw

2. Fuel gauge

3. Fuel joint

4. Fuel tank cap

EMU25831

Fuel joint

This joint is used to connect the fuel line.

EMU25842

Fuel gauge

This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the approximate amount of fuel remaining in the tank.

EMU25851

Fuel tank cap

This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise.

EMU25861

Air vent screw

This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise.

EMU26182

Remote control box

The remote control lever actuates both the shifter and the throttle. The electrical switches are mounted on the remote control box.

1. Power tilt switch

2. Remote control lever

3. Neutral interlock trigger

4. Neutral throttle lever

5. Main switch / choke switch

6. Engine shut-off switch

7. Throttle friction adjuster

EMU26191

Remote control lever

Moving the lever forward from the neutral position engages forward gear. Pulling the lever back from neutral engages reverse. The engine will continue to run at idle until the lever is moved about 35° (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”

4. Shift

5. Fully closed

6. Throttle

7. Fully open

Page 27

Components

TIP:

ZMU06988

ZMU07800

EMU26202

Neutral interlock trigger

To shift out of neutral, first pull the neutral interlock trigger up.

1. Neutral interlock trigger

EMU26213

Neutral throttle lever

To open the throttle without shifting into either forward or reverse, put the remote control lever in the neutral position and lift the neutral throttle lever.

EMU26222

Choke switch

To activate the choke system, press in the main switch while the key is turned to the “ ” (on) or “ ” (start) position. The choke system will then supply the rich fuel mixture required to start the engine. When the key is released, the choke will switch off automatically.

EMU25914

Tiller handle

To change direction, move the tiller handle to the left or right as necessary.

1. Fully open

2. Fully closed

3. Neutral throttle lever

The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.

EMU25925

Gear shift lever

Move the gear shift lever forward to engage the forward gear or rearward to engage the reverse gear.

Page 28

Components

ZMU05338

ZMU05369

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

EMU25943

Throttle grip

The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.

EMU25963

Throttle indicator

The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.

1. Throttle indicator

EMU25977

Throttle friction adjuster

A friction device provides adjustable resistance to movement of the throttle grip or the remote control lever, and can be set according to operator preference. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. WARNING! Do

not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident.

[EWM00033]

Page 29

Components

ZMU05342

When constant speed is desired, tighten the adjuster to maintain the desired throttle setting.

EMU25996

Engine shut-off cord (lanyard) and clip

The clip must be attached to the engine shutoff switch for the engine to run. The cord should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power. WARNING! At-

tach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. Avoid accidentally pulling the cord during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

[EWM00123]

1. Engine shut-off cord (lanyard)

2. Clip

3. Engine shut-off switch

1. Engine shut-off cord (lanyard)

2. Clip

3. Engine shut-off switch

EMU26004

Engine stop button

The engine stop button stops the engine when the button is pushed.

Page 30

Components

TIP:

ZMU07807

EMU26014

Choke knob for pull type

To supply the engine with the rich fuel mixture required to start, pull out this knob.

1. Choke knob

EMU26075

Manual starter handle

The manual starter handle is used to crank and start the engine.

With the main switch in the “ ” (start) position, the starter motor turns to start the engine. When the key is released, it returns automatically to the “ ” (on) position.

EMU26103

Power tilt switch

The power tilt system adjusts the outboard motor angle in relation to the transom. Pushing the switch “ ” (up) tilts the outboard motor up. Pressing the switch “ ” (down) tilts the outboard motor down. When the switch is released, the outboard motor will stop in its current position.

EMU26092

Main switch

The main switch controls the ignition system; its operation is described below.  “” (off) With the main switch in the “ ” (off) position, the electrical circuits are off, and the key can be removed.  “” (on) With the main switch in the “ ” (on) position, the electrical circuits are on, and the key cannot be removed.  “” (start)

For instructions on using the power tilt switch, see pages 47 and 50.

Page 31

EMU31433

WARNING

TIP:

ZMU07813

Steering friction adjuster

A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator preference. An adjuster lever is located on the bottom of the tiller handle bracket. To increase resistance, turn the lever to the port side “A”. To decrease resistance, turn the lever to the starboard side “B”.

EWM00041

Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident.

If the resistance does not increase even when the lever is turned to the port side “A”, make sure that the nut is tightened to the specified torque.

Components

1. Nut

Nut tightening torque:

8 Nm (0.82 kgf-m, 5.9 ft-lb)

 Steering movement is blocked when the

adjuster lever is set to the “A” position.

 Check the tiller handle for smooth move-

ment when the lever is turned to the starboard side “B”.

 Do not apply lubricants such as grease to

the friction areas of the steering friction adjuster.

EMU26263

Trim rod (tilt pin)

The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.

1. Trim rod

Page 32

Components

NOTICE

ZMU07814

EMU30531

Tilt lock mechanism

The tilt lock mechanism is used to prevent the outboard motor from lifting out of the water when in reverse gear.

1. Tilt lock lever

To lock it, set the tilt lock lever in the lock position. To release, push the tilt lock lever in the release position.

EMU26322

Tilt support knob

To keep the outboard motor in the tilted up position, push the tilt support knob under the swivel bracket.

trailered in the normal running position, use an additional support device to secure it in the tilt position.

EMU26334

Tilt support bar

The tilt support bar keeps the outboard motor in the tilted up position.

ECM01661

Do not use the tilt support bar when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position.

EMU26362

Power tilt unit

This unit tilts the outboard motor up and down and is controlled with the power tilt switch.

ECM00631

ECM00661

Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be

Do not step on or exert pressure on the power tilt motor. The power tilt unit could be damaged as a result.

Page 33

Components

NOTICE

TIP:

ZMU07818

ZMU07820

1. Power tilt unit

2. Power tilt motor

ECM00661

Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position.

EMU39264

Cowling lock lever

The cowling lock lever(s) is used to secure the top cowling.

1. Flushing device

For details on usage, see page 59.

EMU26305

Alert indicator

If the engine develops a condition which is cause for alert, the indicator lights up. For details on how to read the alert indicator, see page 29.

1. Low oil pressure-alert indicator

1. Cowling lock lever

EMU26464

Flushing device

This device is used to clean the cooling water passages of the motor using a garden hose and tap water.

Page 34

Instruments and indicators

NOTICE

ZMU07820

EMU36016

EMU36025

Low oil pressure-alert indicator

If oil pressure drops too low, this indicator will light up. For further information, see page 29.

ECM00023

 Do not continue to run the engine if the

low oil pressure-alert indicator is on and the engine oil level is lower. Serious engine damage will occur.

 The low oil pressure-alert indicator does

not indicate the engine oil level. Use the oil dipstick to check the remaining oil quantity. For further information, see page 35.

Indicators

1. Low oil pressure-alert indicator

Page 35

Engine control system

NOTICE

ZMU07904

ZMU02360

EMU26804

Alert system

ECM00092

Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected.

EMU3016C

Low oil pressure alert

If the oil pressure drops too low, the alert device will activate.  The engine speed will automatically de-

crease to about 2000 r/min. If equipped with a low oil pressure-alert indicator, it will light or blink.

If the alert system has activated, stop the engine as soon as it is safe to do so. Check the oil level and add oil as needed. If the oil level is correct and the alert device does not switch off, consult your Yamaha dealer.

 The buzzer will sound (if equipped on the

tiller handle, remote control box, or main switch panel).

Page 36

Installation

WARNING

NOTICE

ZMU07878

EMU26903

Installation

The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Proper mounting depends in part on experience and the specific boat and motor combination.

EWM01591

 Overpowering a boat could cause se-

vere instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.

 Improper mounting of the outboard mo-

tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. For permanently mounted models, your dealer or other person experienced in proper rigging should mount the motor.

EMU34802

Mounting the outboard motor

ECM01681

3. Hold the handgrip and steering bracket as shown in the illustration and lift up the outboard motor using two people.

Do not hold the top cowling when mounting or dismounting the outboard motor. The top cowling could come off, causing the outboard motor to fall.

1. Be sure to mount the outboard motor while the boat is on land. If the boat is on the water, move it to an area on land.

2. To prevent steering movement, turn the adjuster lever to “A” (if equipped with the adjuster lever). To hold the steering bracket easily, raise the tiller handle to the vertical position (if equipped with the tiller handle).

1. Steering bracket

2. Handgrip

Page 37

4. Mount the outboard motor on the center

NOTICE

TIP:

ZMU01760

line (keel line) of the boat, and ensure that the boat itself is well balanced. Otherwise the boat will be hard to steer. For boats without a keel or which are asymmetrical, consult your dealer.

1. Center line (keel line)

EMU26926

Mounting height

To run your boat at optimum efficiency, the water resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting height of the outboard motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine

Installation

speed will rise abnormally and cause the engine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in) below it.

ECM01635

 Make sure that the idle hole is high

enough to prevent water from entering the engine even if the boat is stationary with the maximum load.

 Incorrect engine height or obstructions

to the smooth flow of water (such as the design or condition of the boat, or accessories, such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. If the outboard motor is operated continuously in the presence of airborne water spray, enough water could enter the engine through the air intake opening in the top cowling to cause severe engine damage. Remove the cause of the airborne water spray.

 The optimum mounting height of the out-

board motor is affected by the boat and motor combination and the desired use.

Page 38

Installation

ZMU02012

ZMU02013

ZMU03806

Test runs at different heights can help determine the optimum mounting height. Consult your Yamaha dealer or boat manufacturer for further information on determining the proper mounting height.

 For instructions on setting the trim angle of

the outboard motor, see page 47.

EMU26974

Clamping the outboard motor

1. Place the outboard motor on the transom so that it is positioned as close to the center as possible. Tighten the transom clamp screws evenly and securely. Occasionally check the clamp screws for tightness during operation of the outboard motor because they could become loose due to engine vibration.

WARNING! Loose clamp screws could allow the outboard motor to fall off or move on the transom. This could cause loss of control and serious injury. Make sure the clamp screws are tightened securely. Occasionally check the screws for tightness during operation.

[EWM00643]

the boat. Otherwise the engine could be completely lost if it accidentally falls off the transom.

3. Secure the clamp bracket to the transom using the bolts provided with the outboard (if packed). For details, consult your Yamaha dealer. WARNING! Avoid

using bolts, nuts or washers other than those contained in the engine packaging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tightening, test run the engine and check their tightness.

[EWM00652]

2. If the restraint cable attachment is equipped on your engine, a restraint cable or chain should be used. Attach one end to the restraint cable attachment and the other to a secure mounting point on

1. Bolts

Page 39

Operation

TIP:

WARNING

ZMU01710

EMU36382

First-time operation

EMU36393

Fill engine oil

The engine is shipped from the factory without engine oil. If your dealer did not fill the oil, you must fill it before starting the engine.

NOTICE: Check that the engine is filled with oil before first-time operation to avoid severe engine damage.

The engine is shipped with the following tag, which should be removed after engine oil is filled for the first time. For more information on checking the engine oil level, see page 35.

EMU30175

Breaking in engine

Your new engine requires a period of breakin to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help ensure proper performance and longer engine life. NOTICE: Failure to follow the break-in

procedure could result in reduced engine life or even severe engine damage.

[ECM01782]

[ECM00802]

EMU27086

Procedure for 4-stroke models

Your new engine requires a period of 10 hours break-in to allow mating surfaces of moving parts to wear in evenly.

Run the engine in the water, under load (in gear with a propeller installed) as follows. For 10 hours for breaking in engine avoid extended idling, rough water and crowded areas.

1. For the first hour of operation: Run the engine at varying speeds up to 2000 r/min or approximately half throttle.

2. For the second hour of operation: Increase engine speed as much as necessary to put the boat on plane (but avoid full-throttle operation), then back off on the throttle while keeping the boat at a planing speed.

3. Remaining 8 hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.

4. After the first 10 hours: Operate the engine normally.

EMU36402

Getting to know your boat

All boats have unique handling characteristics. Operate cautiously while you learn how your boat handles under different conditions and various trim angles (see page 47).

EMU36414

Checks before starting engine

EWM01922

If any item in “Checks before starting engine” is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur.

Page 40

Operation

NOTICE

WARNING

ZMU07824

ECM00121

Do not start the engine out of water. Overheating and serious engine damage can occur.

EMU36561

Fuel level

Be sure you have plenty of fuel for your trip. A good rule is to use 1/3 of your fuel to get to the destination, 1/3 to return, and to keep 1/3 as an emergency reserve. With the boat level on a trailer or in the water, check the fuel level. For fuel filling instructions, see page 37.

EMU39841

Removing top cowling

For the following checks, remove the top cowling from the bottom cowling. To remove the top cowling, pull the cowling lock lever up and lift up the top cowling.

1. Cowling lock lever

EMU36443

Fuel system

EWM00061

Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition.

EWM00911

Leaking fuel can result in fire or explosion.

 Check for fuel leakage regularly.

 If any fuel leakage is found, the fuel sys-

tem must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate.

EMU36452

Check for fuel leaks

 Check for fuel leaks or gasoline fumes in

the boat.

 Check for fuel leakage from the fuel sys-

tem.

 Check the fuel tank and fuel lines for

cracks, swellings, or other damages.

EMU36903

Controls

Tiller handle models:  Move the tiller handle fully to the left and

right to make sure operation is smooth.

 Turn the throttle grip from the fully closed

to the fully open position. Make sure that it turns smoothly and that it completely returns to the fully closed position.

 Look for loose or damaged connections of

the throttle and shift cables. Remote control models:  Turn the steering wheel full-right and full-

left. Make sure operation is smooth and un-

restricted throughout the whole range with

no binding or excessive free play.  Operate the throttle levers several times to

make sure there is no hesitation in their

travel. Operation should be smooth over

the complete range of motion, and each le-

ver should return completely to the idle po-

sition.  Look for loose or damaged connections of

the throttle and shift cables.

EMU36484

Engine shut-off cord (lanyard)

Inspect the engine shut-off cord and clip for damage, such as cuts, breaks, and wear.

Page 41

Operation

ZMU06873

ZMU07825

3 2 1

ZMU07792

1. Clip

2. Engine shut-off cord (lanyard)

EMU27168

Engine oil

1. Put the outboard motor in an upright position (not tilted). NOTICE: If the motor

is not level, the oil level indicated on the dipstick may not be accurate.

[ECM01791]

2. Remove oil dipstick and wipe it clean.

1. Oil dipstick

3. Insert the dipstick and remove it again. Be sure to completely insert the dipstick into the dipstick guide, otherwise the oil level measurement will be incorrect.

4. Check the oil level using the dipstick to be sure the level falls between the upper and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark.

1. Oil dipstick

2. Upper mark

3. Lower mark

EMU40412

Outboard motor

 Check that the outboard motor is mounted

properly and check the outboard motor mounting bolts for looseness.

 Check the propeller for damage.  Check for engine oil leaks.

EMU36494

Flushing device

Check that the flushing device’s garden hose connector is securely screwed on to the fitting on the bottom cowling. NOTICE: If the

garden hose connector is not properly connected, cooling water can leak out and the engine can overheat during operation.

[ECM01802]

1. Fitting

2. Flushing device

Page 42

Operation

WARNING

ZMU07827

ZMU07828

ZMU07829

EMU36956

Install top cowling

1. Be sure that the cowling lock lever is released.

2. Be sure that the rubber seal is seated all the way around the top cowling.

1. Top cowling

2. Rubber seal

3. Place the top cowling on the bottom cowling.

4. Check to be sure the rubber seal is seated correctly between the top cowling and the bottom cowling.

5. Move the cowling lock lever to lock the top cowling as shown. NOTICE: If the

top cowling is not installed correctly, water spray under the top cowling can damage the engine, or the top cowling can blow off at high speeds.

[ECM01992]

After installing, check the fitting of the top cowling by pushing it with both hands. If the top cowling is loose, have it repaired by your Yamaha dealer.

EMU34783

Checking power tilt system

EWM01971

 Never get under the lower unit while it is

tilted, even when the tilt support knob is locked. Severe injury could occur if the outboard motor accidentally falls.

 Body parts can be crushed between the

motor and the clamp bracket when the motor is trimmed or tilted.

 Be sure no one is near the outboard mo-

tor before performing this check.

1. Check the power tilt unit for any sign of oil leaks.

2. Operate each of the power tilt switches to check that all switches work.

3. Tilt the outboard motor up and check that the tilt rod is pushed out completely.

1. Cowling lock lever

Page 43

WARNING

1. Tilt rod

ZMU06598

4. Check that the tilt rod is free of corrosion or other flaws.

5. Tilt the outboard motor down. Check that the tilt rod operates smoothly.

EMU36583

Battery

Check that the battery is in good condition, and fully charged. Check that the battery connections are clean, secure and covered by insulating covers. The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start the engine. Refer to the battery manufacturer’s instructions for checks for your particular battery.

EMU2743A

Filling fuel

EWM01831

 Gasoline and its vapors are highly flam-

mable and explosive. Always refuel according to this procedure to reduce the risk of fire and explosion.

 Gasoline is poisonous and can cause in-

jury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin,

Operation

wash with soap and water. If gasoline spills on your clothing, change your clothes.

1. Be sure the engine is stopped.

2. Disconnect the fuel line from the fuel tank and tighten the air vent screw on the fuel tank cap.

3. Remove the portable tank from the boat.

4. Be sure you are in a well-ventilated outdoor area, either securely moored or trailered.

5. Do not smoke and keep away from sparks, flames, static electric discharge, or other sources of ignition.

6. If you use a portable container to store and dispense fuel, use only an approved GASOLINE container.

7. Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.

Page 44

Operation

WARNING

ZMU04484

ZMU07905

8. Fill the fuel tank, but do not overfill.

WARNING! Do not overfill. Otherwise fuel can expand and overflow if the temperature increases.

[EWM02611]

Fuel tank capacity:

12 L (3.17 US gal, 2.64 Imp.gal)

9. Tighten the filler cap securely.

10. Wipe up any spilled gasoline immediately with dry rags. Dispose rags properly according to local laws or regulations.

EMU27453

Operating engine

EWM00421

toms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.

EMU27469

Sending fuel (portable tank)

1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint on the motor, align the fuel joint on the fuel line with the fuel joint on the motor and firmly connect the fuel line to the joint while pinching the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.

 Before starting the engine, make sure

that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.

 When the air vent screw is loosened,

gasoline vapor will be released. Gasoline is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw.

 This product emits exhaust gases which

contain carbon monoxide, a colorless, odorless gas which could cause brain damage or death when inhaled. Symp-

Page 45

TIP:

Wipe up any spilled gasoline immediately

WARNING

TIP:

ZMU02024

with dry rags. Dispose rags properly according to local laws or regulations.

3. Squeeze the primer pump, with the arrow pointing up, until you feel it become firm. During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank.

Operation

EMU34814

Manual start models (tiller control)

EWM01841

 Failure to attached engine shut-off cord

could result in a runaway boat if operator is ejected. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning.

 Avoid accidentally pulling the cord dur-

ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

Starting procedure (cold engine)

1. Place the gear shift lever in neutral.

1. Arrow

EMU27495

Starting engine

EWM01601

Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.

The start-in-gear protection device prevents the engine from starting except when in neutral.

2. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

Page 46

Operation

TIP:

START

ZMU07886

ZMU02030

3. Place the throttle grip in the “ ” (start) position.

4. Pull out the choke knob fully.

5. Pull the manual starter handle slowly until you feel resistance. Then give a strong pull straight out to crank and start the engine.

6. After the engine starts, slowly return the manual starter handle to its original position before releasing it.

7. Slowly return the throttle grip to the fully closed position.

8. Return the choke knob to the home position gradually.

 If the choke knob is left in the “ ” (start)

position while the engine is running, the engine will run poorly or stall.

 When the engine is cold, for example,

when the ambient temperature is low in winter, it needs to be warmed up. For further information, see page 44.

 Do not turn the throttle grip unnecessarily

to open and close the throttle before starting the engine, otherwise the engine may be difficult to start. If the engine is difficult

Page 47

Operation

TIP:

to start, place the throttle grip in the “ ” (warm engine) position and try again.

Starting procedure (warm engine)

1. Place the gear shift lever in neutral.

3. Place the throttle grip in the “ ” (start) position.

4. Pull the manual starter handle slowly until you feel resistance. Then give a strong pull straight out to crank and start the engine.

2. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

 If the engine does not start, place the throt-

tle grip in the “ ” (warm engine) position and try again.

Page 48

Operation

WARNING

TIP:

ZMU02030

OFF

ZMU01880

 It is not necessary to use the choke when

starting a warm engine.

5. After the engine starts, slowly return the manual starter handle to its original position before releasing it.

6. Slowly return the throttle grip to the fully closed position.

EMU34933

Electric start models (remote control)

EWM01841

 Failure to attached engine shut-off cord

 Avoid accidentally pulling the cord dur-

1. Place the remote control lever in neutral.

The start-in-gear protection device prevents the engine from starting except when in neutral.

2. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

3. Turn the main switch to “ ” (on).

Page 49

4. Open the throttle slightly without shifting

TIP:

using the neutral throttle lever.

The neutral throttle lever can only be used when the remote control lever is in neutral.

5. Press in and hold the main switch to operate the remote choke system. (The remote choke system operates only when the main switch is pressed in fully.)

Operation

7. Immediately after the engine starts, release the main switch and allow it to return to “ ” (on). The remote choke system stops operating when the main switch is released. NOTICE: Never turn

the main switch to “ ” (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again.

8. Return the neutral throttle lever to the original position.

[ECM00193]

It is not necessary to use the choke when starting a warm engine.

6. Turn the main switch to “ ” (start) to start the engine.

When the engine is cold, for example, when the ambient temperature is low in winter, it needs to be warmed up. For further information, see page 44.

EMU36511

Checks after starting engine

EMU36524

Cooling water

Check for a steady flow of water from the cooling water pilot hole. A continuous flow of water from the pilot hole indicates that the water pump is pumping water through the

Page 50

Operation

NOTICE

WARNING

NOTICE

ZMU07830

cooling water passages. If the cooling water passages are frozen, it may take a while for water to start flowing out of the pilot hole.

ECM01811

If water is not flowing out of the pilot hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and corrected.

1. Cooling water pilot hole

EMU27671

Warming up engine

EMU27717

Manual start and electric start models

1. After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life.

2. Be sure the low oil pressure-alert indicator goes off after starting the engine.

NOTICE: If the low oil pressure-alert indicator blinks after the engine starts, stop the engine. Otherwise, serious engine damage could occur. Check the oil level and add engine oil if necessary. Consult your Yamaha dealer if the cause for the low oil pressure alert cannot be found.

[ECM01832]

EMU36532

Checks after engine warm up

EMU36542

Shifting

While the boat is tightly moored, and without applying throttle, confirm that the engine shifts smoothly into forward and reverse, and back to neutral.

EMU36981

Stop switches

 Turn the main switch to “ ”, or press the

engine stop button and make sure the engine stops.

 Confirm that removing the clip from the en-

gine shut-off switch stops the engine.

 Confirm that the engine cannot be started

with the clip removed from the engine shutoff switch.

EMU34563

Shifting

EWM00181

Before shifting, make sure there are no swimmers or obstacles in the water near you.

ECM01611

Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral. If this occurs, stop the engine, shift to neutral, then restart the engine and allow it to warm up.

To shift out of neutral

1. Pull the neutral interlock trigger up (if equipped).

Page 51

TIP:

1. Neutral interlock trigger

ZMU07892

ZMU02030

2. Move the remote control lever / gear shift lever firmly and crisply forward (for forward gear) or backward (for reverse gear) [about 35° (a detent can felt) for remote control models]. Be sure to check that the tilt lock lever is in the lock/down position (if equipped) before operating in reverse.

Operation

Tiller handle models: The gear shift lever operates only when the throttle grip is in the fully closed position. To shift from in gear (forward/reverse) to neutral

1. Close the throttle so that the engine slows to idle speed.

Page 52

Operation

WARNING

2. After the engine is at idle speed in gear move the remote control lever / gear shift lever firmly and crisply into the neutral position.

EMU31743

Stopping boat

EWM01511

 Do not use the reverse function to slow

down or stop the boat as it could cause you to lose control, be ejected, or impact the steering wheel or other parts of the boat. This could increase the risk of serious injury. It could also damage the shift mechanism.

 Do not shift into reverse while traveling

at planing speeds. Loss of control, boat swamping, or damage to the boat could occur.

The boat is not equipped with a separate braking system. Water resistance stops it after the throttle lever is moved back to idle. The stopping distance varies depending on gross weight, water surface conditions, and wind direction.

EMU27822

Stopping engine

Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stopping the engine immediately after operating at high speed is not recommended.

EMU27834

Procedure

1. Push and hold the engine stop button until the engine comes to a complete stop.

2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped.

Page 53

3. Disconnect the fuel line if you are using

TIP:

WARNING

ZMU07906

an external fuel tank.

If the outboard motor is equipped with an engine shut-off cord, the engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch.

EMU27855

Procedure

1. Turn the main switch to “ ” (off).

Operation

The engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch, then turning the main switch to “ ” (off).

EMU27863

Trimming outboard motor

EWM00741

Excessive trim for the operating conditions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.

The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help improve performance and fuel economy while reducing strain on the engine. Correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.

2. After stopping the engine, disconnect the fuel line or close the fuel cock if there is a fuel joint or a fuel cock on the boat.

3. Tighten the air vent screw on the fuel tank cap (if equipped).

4. Remove the key if the boat will be left unattended.

1. Trim operating angle

Page 54

Operation

WARNING

TIP:

WARNING

TIP:

ZMU07831

EMU27873

Adjusting trim angle for manual tilt models

There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle.

1. Stop the engine.

2. Tilt the outboard motor up, and then remove the trim rod from the clamp bracket.

1. Trim rod

3. Reposition the rod in the desired hole.

To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod toward the transom. Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.

EWM00401

 Stop the engine before adjusting the

trim angle.

 Use care to avoid being pinched when

removing or installing the rod.

 Use caution when trying a trim position

for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.

The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole.

EMU27906

Adjusting trim angle (power tilt models)

EWM00754

 Be sure all people are clear of the out-

board motor when adjusting the trim angle. Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted.

 Use caution when trying a trim position

for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.

 If equipped with a power trim and tilt

switch located on the bottom cowling, use the switch only when the boat is at a complete stop with the engine off. Do not adjust the trim angle with this switch while the boat is moving.

1. Move the gear shift lever to the neutral position.

While the boat is moving, it may be difficult to adjust the trim angle due to water pressure. Before adjusting the trim angle, reduce the boat speed and shift into neutral.

2. Tilt the outboard motor to the desired angle using the power tilt switch.

Page 55

To raise the bow (“trim-out”), tilt the outboard

TIP:

motor up. To lower the bow (“trim-in”), tilt the outboard motor down. Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.

Stay within the trim operating angle when trimming the outboard motor using the power tilt system.

EMU27913

Adjusting boat trim

When the boat is on plane, a bow-up attitude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.

Operation

Bow Up

Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces performance further, and the boat may “porpoise” (hop in the water), which could throw the operator and passengers overboard.

Bow Down

Too much trim-in causes the boat to “plow” through the water, decreasing fuel economy and making it hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making operation difficult and dangerous.

Page 56

Operation

TIP:

WARNING

NOTICE

ZMU07906

Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.

EMU27936

Tilting up and down

If the engine will be stopped for some time or if the boat is moored in shallows, the outboard motor should be tilted up to protect the propeller and lower casing from damage by collision with obstructions, and also to reduce salt corrosion.

EWM00223

Make sure that no one is near the outboard motor when tilting the outboard motor up or down. Otherwise, body parts could be crushed between the outboard motor and the clamp bracket.

EWM00251

Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.

ECM00242

EMU2797C

Procedure for tilting up (manual tilt models)

1. Place the remote control lever / gear shift lever in neutral.

2. Disconnect the fuel line from the outboard motor.

 Before tilting the outboard motor, stop

the engine by following the procedure on page 46. Never tilt the outboard motor while the engine is running. Severe damage from overheating can result.

 Do not tilt up the engine by pushing the

tiller handle (if equipped) because this could break the handle.

3. Place the tilt lock lever (if equipped) in the release/up position.

Page 57

Operation

ZMU03196

4. Pull up the shallow water lever (if equipped).

5. Hold the rear of the top cowling with one hand and tilt the engine up fully.

6. Push the tilt support knob into the clamp bracket. Or the tilt support bar will turn to the lock position automatically. NOTICE:

EMU44610

Procedure for tilting up (power tilt

[ECM01642]

models)

1. Place the remote control lever in neutral.

2. Press the power tilt switch “ ” (up) until the outboard motor has tilted up completely.

3. Push the tilt support knob into the clamp bracket to support the engine.

WARNING! After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit or in the power tilt unit loses pressure.

[EWM00263]

NOTICE: Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position. For more detailed information, see page 55.

[ECM01642]

Page 58

Operation

WARNING

ZMU07892

ZMU01936

EMU30193

Procedure for tilting down (manual tilt models)

1. Place the tilt lock lever in the lock position.

2. Slightly tilt the engine up until the tilt support bar is automatically released.

3. Slowly tilt the engine down.

EMU44620

Procedure for tilting down (power tilt models)

1. Push the power tilt switch “ ” (up) until the outboard motor is supported by the tilt rod and the tilt support knob becomes free.

2. Pull out the tilt support knob.

3. Push the power tilt switch “ ” (down) to lower the outboard motor to the desired position.

EMU28063

Shallow water

EMU28074

Cruising in shallow water (manual tilt models)

EWM01782

 Run the boat at the lowest possible

speed when using the shallow water cruising system. The tilt lock mechanism does not work while the shallow water cruising system is being used. Hitting an underwater obstacle could cause the outboard motor to lift out of the water, resulting in loss of control.

Page 59

 Use extra care when operating in re-

NOTICE

verse. Too much reverse thrust can cause the outboard motor to lift out of the water, increasing the chance of accident and personal injury.

ECM00261

Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when setting up for and cruising in shallow water. Otherwise severe damage from overheating can result.

Operation

2. Place the tilt lock lever in the release/up position.

EMU28126

Procedure

1. Place the remote control lever / gear shift lever in neutral.

3. Slightly tilt the outboard motor up. The tilt support bar will lock automatically, supporting the outboard motor in a partially raised position. This outboard motor has 2 positions for shallow water cruising.

4. To return the outboard motor to the normal running position, place the remote control lever / gear shift lever in neutral.

Page 60

Operation

NOTICE

ZMU07892

ZMU01935

5. Place the tilt lock lever in the lock/down position, then slightly tilt the outboard motor up until the tilt support bar automatically returns to the free position.

6. Slowly lower the outboard motor to the normal position.

EMU32862

Power tilt models

The outboard motor can be tilted up partially to allow operation in shallow water.

ECM00261

EMU32953

Procedure for power tilt models

1. Place the remote control lever in neutral.

2. Slightly tilt the outboard motor up to the desired position using the power tilt switch. WARNING! Using the power tilt

switch on the bottom cowling while the boat is moving or engine is on could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.

[EWM01961]

3. To return the outboard motor to the normal running position, press the power tilt switch and slowly tilt the outboard motor down.

EMU35392

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh water.

Cruising in muddy, turbid, or acidic water

Water in some areas can be acidic or with a lot of sediment in it, such as muddy or turbid (cloudy) water. After operating in such water, flush the cooling passages with fresh water to prevent corrosion. Also rinse the outside of the outboard motor with fresh water.

Page 61

Maintenance

WARNING

NOTICE

ZMU07906

EMU2822B

Transporting and storing out-

board motor

EWM02621

 USE CARE when transporting fuel tank,

whether in a boat or car.

 DO NOT fill fuel container to maximum

capacity. Gasoline will expand considerably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.

 Leaking fuel is a fire hazard. When

transporting and storing the outboard motor, disconnect the fuel line from the outboard motor to prevent fuel from leaking.

 Never get under the outboard motor

while it is tilted. Severe injury could occur if the outboard motor accidentally falls.

 Do not use the tilt support lever or knob

when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the outboard motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position.

ECM02441

 Disconnect the fuel line from the outboard

motor.

 Tighten the fuel tank cap and its air vent

screw.

 When the outboard motor is tilted pro-

longed time for mooring or trailering the boat, disconnect the fuel line from the outboard motor. Tighten the fuel tank cap and

its air vent screw. The outboard motor should be transported and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilt position using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.

EMU34822

Dismounting the outboard motor

ECM01681

Do not hold the top cowling when mounting or dismounting the outboard motor. The top cowling could come off, causing the outboard motor to fall.

1. Stop the engine and land the boat.

2. Disconnect the fuel line from the out-

board motor.

When storing the outboard motor for prolonged time, fuel must be drained from the fuel tank. The deteriorated fuel could clog the fuel line causing engine start difficulty or malfunction.

When storing or transporting the outboard motor, make sure to follow the procedure listed below.

3. For electric start models, disconnect the

battery cables from the battery terminals.

Page 62

Maintenance

ZMU07878

4. To prevent steering movement, turn the adjuster lever to “A” (if equipped with the adjuster lever). To hold the steering bracket easily, raise the tiller handle to the vertical position (if equipped with the tiller handle).

5. Loosen the clamp screw(s).

6. Hold the handgrip and steering bracket as shown in the illustration and lift up the outboard motor to dismount it from the boat.

1. Steering bracket

2. Handgrip

7. When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown or use an outboard motor stand.

Page 63

TIP:

When transporting the outboard motor in a

NOTICE

horizontal position, place a towel or something similar under the outboard motor to protect it from damage.

EMU28242

Storing outboard motor

When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the following procedures.

ECM01081

 To prevent problems which can be

caused by oil entering the cylinder from the sump, keep the outboard motor in

Maintenance

the attitude shown when transporting and storing it. If storing or transporting the outboard motor on its side (not upright), put it on a cushion after draining the engine oil.

 Do not place the outboard motor on its

side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trouble.

 Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28306

Procedure

EMU32027

Flushing in a test tank

ECM00302

Before starting the engine, make sure to supply water to the cooling water passages. Otherwise, the engine could overheat and be damaged.

1. Dismount the outboard motor from the boat. For further details, see page 55.

2. Wash the outboard motor body using fresh water. NOTICE: Do not spray wa-

ter into the air intake.

information, see page 59.

3. Disconnect the fuel line from the outboard motor.

4. Remove the top cowling and silencer cover/cap, if equipped. Remove the propeller. For further details, see page 69.

5. Position the outboard motor on a water tank. For further details, see page 30.

6. Fill the tank with fresh water until the anticavitation plate is immersed in water.

NOTICE: If the fresh water level is below the level of the anti-cavitation

[ECM01841] For further

Page 64

Maintenance

ZMU02051

ZMU07891

plate, or if the water supply is insufficient, engine seizure may occur.

[ECM00292]

1. Water surface

2. Lowest water level

7. Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flushing and fogging at the same time.

WARNING! Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.

8. Run the engine at a fast idle for a few minutes in neutral position.

9. Just prior to turning off the engine, quickly spray “Fogging Oil” alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke excessively and almost stall.

[EWM00092]

10. Remove the outboard motor from the test tank.

11. Install the silencer cover/cap of fogging hole (if equipped) and top cowling.

12. If the “Fogging Oil” is not available, run the engine at a fast idle until the fuel system becomes empty and the engine stops.

13. Drain the cooling water completely out of the motor. Clean the body thoroughly.

14. If the “Fogging Oil” is not available, remove the spark plug(s). Pour a teaspoonful of clean engine oil into each cylinder. Crank several times manually. Replace the spark plug(s).

15. Drain the fuel from the fuel tank.

16. Store the fuel tank in a dry, well-ventilated place, not in direct sunlight.

EMU41072

Lubrication

1. Change the gear oil. For instructions, see page 70. Check the gear oil for the presence of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.

2. Lubricate all grease fittings. For further details, see page 64.

Page 65

TIP:

For long-term storage, fogging the engine

NOTICE

TIP:

with fogging oil is recommended. Contact your Yamaha dealer for information about fogging oil and procedures for your outboard motor.

EMU28446

Flushing power unit

Perform this procedure right after operation for the most thorough flushing.

ECM01531

Do not perform this procedure while the engine is running. The water pump may be damaged and severe damage from overheating can result.

1. After shutting off the engine, unscrew the garden hose connector from the fitting on the bottom cowling.

Maintenance

3. Garden hose adapter

2. Screw the garden hose adapter onto a garden hose, which is connected to a fresh water supply, and then connect it to the garden hose connector.

3. With the engine off, turn on the water tap and let the water flush through the cooling passages for about 15 minutes. Turn off the water and disconnect the garden hose adapter from the garden hose connector.

4. Reinstall the garden hose connector onto the fitting on the bottom cowling. Tighten the connector securely.

NOTICE: Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal operation. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fitting after flushing the engine.

[ECM00542]

1. Fitting

2. Garden hose connector

 When flushing the engine with the boat in

the water, tilting up the outboard motor until it is completely out of the water will achieve better results.

 For cooling system flushing instructions,

see page 55.

EMU44341

Cleaning the outboard motor

When cleaning the outboard motor, the top cowling must be installed.

1. Wash the exterior of the outboard motor using fresh water. NOTICE: Do not

spray water into the air intake.

[ECM01841]

Page 66

Maintenance

WARNING

ZMU07862

1. Air intake

2. Drain the cooling water completely out of the outboard motor. Clean the body thoroughly.

EMU28462

Checking painted surface of outboard motor

Check the outboard motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer.

EMU37004

Periodic maintenance

EWM01943

These procedures require mechanical skills, tools, and supplies. If you do not have the proper skills, tools, or supplies to perform a maintenance procedure, have a Yamaha dealer or other qualified mechanic do the work. The procedures involve disassembling the motor and exposing dangerous parts. To reduce the risk of injury from moving, hot, or electrical parts:  Turn off the engine and keep the key(s)

and engine shut-off cord (lanyard) with you when you perform maintenance unless otherwise specified.

 The power tilt switch operate even when

the ignition key is off. Keep people away from the switches whenever working around the motor. When the motor is tilted, keep away from the area under it or between it and the clamp bracket. Be sure no one is in this area before operating the power tilt mechanism.

 Allow the engine to cool before handling

hot parts or fluids.

 Always completely reassemble the mo-

tor before operation.

EMU28512

Replacement parts

If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from your Yamaha dealer.

EMU34152

Severe operating conditions

Severe operating conditions involve one or more of the following types of operation on a regular basis:  Operating continuously at or near maxi-

mum engine speed (rpm) for many hours

 Operating continuously at a low engine

speed (rpm) for many hours

 Operating without sufficient time for engine

to warm up and cool down

 Frequent quick acceleration and decelera-

tion

 Frequent shifting  Frequently starting and stopping the en-

gine(s)

 Operation that fluctuates often between

light and heavy cargo loads Outboard motors operating under any of these above conditions require more frequent maintenance. Yamaha recommends

Page 67

Maintenance

TIP:

that you do this service twice as often as specified in the maintenance chart. For example, if a particular service should be done

EMU34448

at 50 hours, do it instead at 25 hours. This will help prevent more rapid deterioration of engine components.

Maintenance chart 1

 Refer to the sections in this chapter for explanations of each owner-specific action.  The maintenance cycle on these charts assume usage of 100 hours per year and regular

flushing of the cooling water passages. Maintenance frequency should be adjusted when operating the engine under adverse conditions such as extended trolling.

 Disassembly or repairs may be necessary depending on the outcome of maintenance

checks.

 Expendable or consumable parts and lubricants will lose their effectiveness over time and

through normal usage regardless of the warranty period.

 When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should

be flushed with clean water after each use. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Initial Every

Item Actions

Anode(s) (external)

Anode(s) (cylinder head)

Battery (electrolyte level, terminal)

Cooling water leakage

Cowling lock lever Inspection

Engine starting condition/noise

Engine idle speed/noise

Engine oil Replacement

Engine oil filter (built into oil pan)

Inspection or replacement as necessary

Replacement

Inspection

Fill, charging or replacing as necessary

Inspection or replacement as necessary

Inspection

Inspection, cleaning or replacement as necessary

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

Page 68

Maintenance

Item Actions

Fuel filter (disposal type)

Fuel line Inspection

Fuel line

Fuel pump

Fuel/engine oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Clamp bracket bolt (through tube)

Impeller/water pump housing

Power tilt unit Inspection

Propeller/propeller nut/cotter pin

Shift link/shift cable

Spark plug(s)

Spark plug caps/spark plug wires

Water from the cooling water pilot hole

Throttle link/throttle cable

Thermostat

Timing belt

Valve clearance

Cooling water inlet Inspection

Main switch/stop switch/choke switch

Replacement

Inspection or replacement as necessary

Inspection and greasing

Inspection or replacement as necessary

Replacement

Inspection or replacement as necessary

Inspection, adjustment or replacement as necessary

Inspection or replacement as necessary

Inspection

Inspection, adjustment or replacement as necessary

Inspection or replacement as necessary

Inspection and adjustment

Inspection or replacement as necessary

Initial Every

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

Page 69

Item Actions

Wire harness connections/wire coupler connections

Fuel tank (Yamaha portable tank)

EMU34452

Inspection or replacement as necessary

Inspection and cleaning as necessary

Maintenance chart 2

Item Actions

Exhaust guide/exhaust manifold

Timing belt Replacement

Inspection or replacement as necessary

Maintenance

Initial Every

20 hours

(3 months)

100 hours

(1 year)

Every

1000 hours

300 hours

(3 years)

500 hours

(5 years)

Page 70

Maintenance

ZMU06671

EMU28944

Greasing

Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft)

Page 71

Maintenance

TIP:

ZMU07835

EMU44491

Cleaning and adjusting spark plug

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

1. Remove the spark plug caps from the

spark plugs.

3. Be sure to use the specified spark plug, otherwise the engine may not operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; replace it if out of specification.

1. Spark plug gap

2. Spark plug part number

3. Spark plug I.D. mark (NGK)

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

4. When fitting the plug, wipe off any dirt from the threads, and then screw it in to the correct torque.

1. Spark plug cap

2. Remove the spark plug. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type. WARNING!

When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.

[EWM00562]

Standard spark plug:

BR6HS-10

Spark plug torque:

24 Nm (2.45 kgf-m, 17.7 ft-lb)

If a torque-wrench is not available when you are reinstalling a spark plug, a good estimate of the correct torque is 1/12 turn past fingertight. When you are installing a new spark plug, a good estimate of the correct torque is 1/2 to 2/3 turn past finger-tight.

Page 72

Maintenance

WARNING

NOTICE

WARNING

NOTICE

ZMU07836

EMU28992

Checking fuel filter

Check the fuel filter periodically. The fuel filter is a one piece, disposable type. If foreign matter is found in the filter, replace it. For replacement of the fuel filter, consult your Yamaha dealer.

1. Fuel filter

EMU29045

Inspecting idle speed

EWM00452

 Do not touch or remove electrical parts

when starting or during operation.

 Keep hands, hair, and clothes away

from the flywheel and other rotating parts while the engine is running.

ECM00491

This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used.

If the boat is not equipped with a tachometer for the outboard motor, use a diagnostic tachometer for this procedure. Results may vary depending on whether testing is conducted with the flushing attachment, in a test tank, or with the outboard motor in the water.

1. Start the engine and allow it to warm up fully in neutral until it is running smoothly.

2. Once the engine has warmed up, verify whether the idle speed is set to specification. For idle speed specifications, see page 10. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic.

EMU38807

Changing engine oil

EWM00761

 Avoid draining the engine oil immediate-

ly after stopping the engine. The oil is hot and should be handled with care to avoid burns.

 Be sure the outboard motor is securely

fastened to the transom or a stable stand.

ECM01711

Change the engine oil after the first 20 hours of operation or 3 months, and every 100 hours or at 1-year intervals thereafter. Otherwise the engine will wear quickly.

To prevent spilling oil where it could cause damage to nature, it is strongly recommended that you use an oil changer to change the engine oil. If an oil changer is not available, drain the engine oil by removing the drain screw. If you are not familiar with the procedure for changing the engine oil, consult your Yamaha dealer.

1. Put the outboard motor in an upright position (not tilted). NOTICE: If the out-

board motor is not level, the oil level indicated on the oil dipstick may not be accurate.

[ECM01862]

Page 73

2. Start the engine. Warm it up and keep

TIP:

ZMU02270

ZMU06620

ZMU07967

the idle speed for 5-10 minutes.

3. Stop the engine and leave it for 5-10 minutes.

4. Remove the top cowling.

5. Remove the oil filler cap. Pull out the dipstick and use the oil changer to extract the oil completely.

Maintenance

When using an oil changer, skip steps 6 and

6. Prepare a suitable container that holds a larger amount than the engine oil capacity. Remove the drain screw and gasket while holding the container under the drain hole. Let the oil drain completely. Wipe up any spilled oil immediately.

1. Drain screw

2. Gasket

1. Oil filler cap

1. Oil changer

If the oil does not drain easily, change the tilt angle or turn the outboard motor to port and starboard to drain the oil.

7. Put a new gasket on the oil drain screw. Apply a light coat of oil to the gasket and install the drain screw.

Drain screw tightening torque:

24 Nm (2.45 kgf-m, 17.7 ft-lb)

If a torque wrench is not available when you are installing the drain screw, finger tighten the screw just until the gasket comes into contact with the surface of the drain hole. Then tighten 1/4 to 1/2 turn more. Tighten the drain screw to the correct torque with a torque wrench as soon as possible.

Page 74

Maintenance

TIP:

WARNING

3 2 1

ZMU07792

ZMU07837

8. Add the correct amount of oil through the filler hole. Put back the filler cap and the dipstick. NOTICE: Overfilling the oil

could cause leakage or damage. If the oil level is above the upper level mark, drain until the level meets the specified capacity.

[ECM01851]

Recommended engine oil:

YAMALUBE 4 or 4-stroke outboard motor oil

Engine oil quantity:

0.8 L (0.85 US qt, 0.70 Imp.qt)

9. Leave the outboard motor for 5-10 minutes.

10. Remove the oil dipstick and wipe it clean.

11. Insert the dipstick and remove it again. Be sure to completely insert the dipstick into the dipstick guide, otherwise the oil level measurement will be incorrect.

12. Recheck the oil level using the dipstick to be sure the level falls between the upper and lower marks. Consult your Yamaha dealer if the oil level is out of specified level.

leaks. NOTICE: If the low oil pressure-

alert indicator comes on or if there are oil leaks, stop the engine and find the cause. Continued operation with a problem could cause severe engine damage. Consult your Yamaha dealer if the problem cannot be located and corrected.

[ECM01623]

14. Install the top cowling.

15. Dispose of used oil according to local regulations.

 For more information on the disposal of

used oil, consult your Yamaha dealer.

 Change the oil more often when operating

the engine under adverse conditions such as extended trolling.

EMU29115

Inspecting wiring and connectors

 Inspect that each connector is engaged se-

curely.

 Inspect that each ground lead is properly

secured.

1. Oil dipstick

2. Upper mark

3. Lower mark

13. Start the engine and make sure that the low oil pressure-alert indicator remains off. Also, make sure that there are no oil

EMU32113

Checking propeller

EWM01882

You could be seriously injured if the engine accidentally starts when you are near the propeller. Before inspecting, removing, or installing the propeller, place the shift control in neutral, turn the main

Page 75

Maintenance

ZMU07969

ZMU07970

switch to “ ” (off) and remove the key, and remove the clip from the engine shutoff switch. Turn off the battery cut-off switch if your boat has one.

Do not use your hand to hold the propeller when loosening or tightening the propeller nut. Put a wood block between the anti-cavitation plate and the propeller to prevent the propeller from turning.

Checkpoints  Check each of the propeller blades for ero-

sion from cavitation or ventilation, or other damage.

 Check the propeller shaft for damage.  Check the splines for wear or damage.  Check for fish line tangled around the pro-

peller shaft.

EMU30663

Removing propeller

EMU29198

Spline models

1. Straighten the cotter pin and pull it out using a pair of pliers.

2. Remove the propeller nut, washer, and spacer (if equipped). WARNING! Do not

use your hand to hold the propeller when loosening the propeller nut.

[EWM01891]

1. Cotter pin

2. Propeller nut

3. Washer

4. Propeller

5. Thrust washer

 Check the propeller shaft oil seal for dam-

age.

1. Cotter pin

2. Propeller nut

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

Page 76

Maintenance

NOTICE

TIP:

WARNING

3. Remove the propeller, washer (if equipped), and thrust washer.

EMU30673

Installing propeller

EMU29235

Spline models

ECM00502

Make sure to use a new cotter pin and bend the ends over securely. Otherwise, the propeller could come off during operation and be lost.

1. Apply Yamaha marine grease or a corrosion resistant grease to the propeller shaft.

2. Install the spacer (if equipped), thrust washer, washer (if equipped), and propeller on the propeller shaft. NOTICE:

Make sure to install the thrust washer before installing the propeller. Otherwise, the lower case and propeller boss could be damaged.

[ECM01882]

3. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.

Propeller nut tightening torque:

F9.9JE 17 Nm (1.73 kgf-m, 12.5 ft-lb) F9.9JMH 17 Nm (1.73 kgf-m,

12.5 ft-lb) FT9.9LE 21 Nm (2.14 kgf-m,

15.5 ft-lb) FT9.9LEP 21 Nm (2.14 kgf-m,

15.5 ft-lb) FT9.9LMH 21 Nm (2.14 kgf-m,

15.5 ft-lb)

4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.

NOTICE: Do not reuse the cotter pin. Otherwise, the propeller can come off during operation.

[ECM01892]

If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole.

EMU2928C

Changing gear oil

EWM00801

 Be sure the outboard motor is securely

fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you.

 Never get under the lower unit while it is

tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidentally falls.

1. Tilt the outboard motor so that the gear oil drain screw is at the lowest point possible.

2. Place a suitable container under the gear case.

3. Remove the gear oil drain screw and gasket. NOTICE: If there is an exces-

sive quantity of metal particles on the magnetic gear oil drain screw, this can indicate lower unit problem. Consult your Yamaha dealer.

[ECM01901]

Page 77

TIP:

1. Gear oil drain screw

ZMU06685

ZMU06686

2. Oil level plug

 If a magnetic gear oil drain screw is

equipped, remove all metal particles from the screw before installing it.

 Always use new gaskets. Do not reuse the

removed gaskets.

4. Remove the oil level plug and gasket to allow the oil to drain completely.

NOTICE: Check the used gear oil after it has been drained. If the gear oil is milky or contains water or a large amount of metal particles, the gear case may be damaged. Have a Yamaha dealer check and repair the outboard motor.

For disposal of used oil, consult your Yamaha dealer.

5. Put the outboard motor in a vertical position. Using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole.

[ECM00714]

Maintenance

Recommended gear oil:

YAMALUBE outboard gear oil or Hypoid gear oil

Recommended gear oil grade:

SAE 90 API GL-4

Gear oil quantity:

F9.9JE 0.150 L (0.159 US qt,

0.132 Imp.qt) F9.9JMH 0.150 L (0.159 US qt,

0.132 Imp.qt) FT9.9LE 0.370 L (0.391 US qt,

0.326 Imp.qt) FT9.9LEP 0.370 L (0.391 US qt,

0.326 Imp.qt) FT9.9LMH 0.370 L (0.391 US qt,

0.326 Imp.qt)

6. Put a new gasket on the oil level plug. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.

Tightening torque:

9 Nm (0.92 kgf-m, 6.6 ft-lb)

7. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.

Tightening torque:

9 Nm (0.92 kgf-m, 6.6 ft-lb)

Page 78

Maintenance

WARNING

ZMU03231

EMU29304

Cleaning fuel tank

EWM00921

Gasoline is highly flammable, and its vapors are flammable and explosive.  If you have any question about properly

doing this procedure, consult your Yamaha dealer.

 Keep away from sparks, cigarettes,

flames, or other sources of ignition when cleaning the fuel tank.

 Remove the fuel tank from the boat be-

fore cleaning it. Work only outdoors in an area with good ventilation.

 Wipe up any spilled fuel immediately.  Reassemble the fuel tank carefully. Im-

proper assembly can result in a fuel leak, which could result in a fire or explosion hazard.

 Dispose of old gasoline according to lo-

cal regulations.

1. Empty the fuel tank into an approved container.

2. Pour a small amount of suitable solvent into the tank. Install the cap and shake the tank. Drain the solvent completely.

3. Remove the screws holding the fuel joint assembly. Pull the assembly out of the tank.

4. Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry.

5. Replace the gasket with a new one. Reinstall the fuel joint assembly and tighten the screws firmly.

Page 79

EMU29317

NOTICE

TIP:

WARNING

NOTICE

ZMU07838

ZMU07879

ZMU07880

Inspecting and replacing anode(s)

Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.

ECM00721

Maintenance

Do not paint anodes, as this would render them ineffective.

1. Anode

Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit.

EMU29324

Checking battery (for electric start models)

EWM01903

Battery electrolyte is poisonous and caustic, and batteries generate explosive hydrogen gas. When working near the battery:  Wear protective eye gear and rubber

gloves.

 Do not smoke or bring any other source

of ignition near the battery.

The procedure for checking the battery varies for different batteries. This procedure contains typical checks that apply to many batteries, but you should always refer to the battery manufacturer’s instructions.

ECM01921

A poorly maintained battery will quickly deteriorate.

1. Check the electrolyte level.

Page 80

Maintenance

WARNING

NOTICE

ZMU01811

2. Check the battery’s charge. If your boat is equipped with the digital speedometer, the voltmeter and low battery alert functions will help you monitor the battery’s charge. If the battery needs charging, consult your Yamaha dealer.

3. Check the battery connections. They should be clean, secure, and covered by an insulating cover. WARNING! Bad

connections can produce shorting or arcing and cause an explosion.

EMU29335

[EWM01913]

Connecting the battery

EWM00573

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder.

ECM01125

Do not reverse the battery cables. Otherwise, the electrical parts could be damaged.

1. Red cable

2. Black cable

3. Battery

3. The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine.

EMU29372

Disconnecting the battery

1. Turn off the battery cut-off switch (if equipped) and main switch. NOTICE: If

they are left on, the electrical system can be damaged.

2. Disconnect the negative cable(s) from the negative (-) terminal. NOTICE: Al-

ways disconnect all negative (-) cables first to avoid a short circuit and damage to the electrical system.

3. Disconnect the positive cable(s) and remove the battery from the boat.

4. Clean, maintain, and store the battery according to the manufacturer’s instructions.

[ECM01931]

[ECM01941]

1. Make sure the main switch (on applicable models) is “ ” (off) before working on the battery.

2. Connect the red battery cable to the POSITIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) terminal.

Page 81

Trouble Recovery

EMU29428

Troubleshooting

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-alert indicator is flashing, consult your Yamaha dealer.

Starter will not operate.

Q. Is battery capacity weak or low? A. Check battery condition. Use battery of recommended capacity.

Q. Are battery connections loose or corroded? A. Tighten battery cables and clean battery terminals.

Q. Is fuse for electric start relay or electric circuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct amperage.

Q. Are starter components faulty? A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear? A. Shift to neutral.

Engine will not start (starter operates).

Q. Is fuel tank empty? A. Fill tank with clean, fresh fuel.

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Is starting procedure incorrect? A. See page 39.

Q. Has fuel pump malfunctioned? A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Q. Are spark plug cap(s) fitted incorrectly? A. Check and re-fit cap(s).

Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.

Q. Are ignition parts faulty? A. Have serviced by a Yamaha dealer.

Q. Is engine shut-off cord (lanyard) not attached? A. Attach cord.

Q. Are engine inner parts damaged? A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Page 82

Trouble Recovery

Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.

Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.

Q. Has alert system activated? A. Find and correct cause of alert.

Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.

Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.

Q. Is specified engine oil not being used? A. Check and replace oil as specified.

A. Return to home position.

Q. Is motor angle too high? A. Return to normal operating position.

Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect? A. Connect correctly.

Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer.

Q. Is battery cable disconnected? A. Connect securely.

Alert buzzer sounds or indicator lights.

Q. Is cooling system clogged? A. Check water intake for restriction.

Q. Is engine oil level low? A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type.

Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer.

Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.

Q. Is air vent screw on fuel tank closed? A. Open air vent screw.

Q. Is choke knob pulled out?

Q. Is specified engine oil not being used? A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorated? A. Replace oil with fresh, specified type.

Q. Is oil filter clogged? A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunctioned?

Page 83

Trouble Recovery

A. Have serviced by a Yamaha dealer.

Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane.

Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer.

Q. Is there excess water in fuel filter cup? A. Drain filter cup.

Engine power loss.

Q. Is propeller damaged? A. Have propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect? A. Install correct propeller to operate outboard at its recommended speed (r/min) range.

Q. Is trim angle incorrect? A. Adjust trim angle to achieve most efficient operation.

Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.

Q. Are weeds or other foreign matter tangled on gear housing? A. Remove foreign matter and clean lower unit.

Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.

Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.

Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.

Q. Have electrical parts failed? A. Have serviced by a Yamaha dealer.

Q. Is specified fuel not being used? A. Replace fuel with specified type.

Q. Has alert system activated? A. Find and correct cause of alert.

Q. Is boat bottom fouled with marine growth? A. Clean boat bottom.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Q. Is specified engine oil not being used? A. Check and replace oil with specified type.

Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed? A. Open the air vent screw.

Q. Is fuel pump damaged?

Page 84

Trouble Recovery

WARNING

A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect? A. Connect correctly.

Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type.

Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.

Q. Is propeller damaged? A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangled on propeller? A. Remove and clean propeller.

Q. Is motor mounting bolt loose? A. Tighten bolt.

Q. Is steering pivot loose or damaged? A. Tighten or have serviced by a Yamaha dealer.

EMU29434

Temporary action in emergen-

EMU29442

Impact damage

EWM00871

The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate.

If the outboard motor hits an object in the water, follow the procedure below.

1. Stop the engine immediately.

2. Check the control system and all components for damage. Also, check the boat for damage.

3. Whether damage is found or not, return to the nearest harbor slowly and carefully.

4. Have a Yamaha dealer check the outboard motor before operating it again.

EMU30684

Replacing fuse

If a fuse has blown, open the fuse holder and remove the fuse with a fuse puller. Replace it with a spare one of the proper amperage.

Page 85

Trouble Recovery

WARNING

EWM00632

Substituting an incorrect fuse or a piece of wire could allow excessive current flow. This could cause electric system damage and a fire hazard.

Consult your Yamaha dealer if the new fuse immediately blows again.

1. Fuse box

2. Fuse (10 A)

3. Spare fuse (10 A)

4. Fuse puller

EMU32131

Power tilt will not operate

If the engine cannot be tilted up or down with the power tilt because of a discharged battery or a failure with the power tilt unit, the engine can be tilted manually.

1. Loosen the manual valve screw by turning it counterclockwise until it stops.

1. Manual valve screw

2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise.

EMU29534

Starter will not operate

If the starter mechanism does not operate (the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.

EWM01023

 Use this procedure only in an emergen-

cy to return to the nearest port for repairs.

 When the emergency starter rope is

used to start the engine, the start-ingear protection device does not operate. Make sure the remote control lever is in neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.

 Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg while operating the boat.

 Do not attach the cord to clothing that

could tear loose. Do not route the cord where it could become entangled, preventing it from functioning.

 Avoid accidentally pulling the cord dur-

 Make sure no one is standing behind

you when pulling the starter rope. It could whip behind you and injure someone.

 An unguarded, rotating flywheel is very

dangerous. Keep loose clothing and other objects away when starting the

Page 86

Trouble Recovery

OFF

ZMU01880

ZMU07907

engine. Use the emergency starter rope only as instructed. Do not touch the flywheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.

 Do not touch the ignition coil, spark plug

wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an electrical shock.

EMU29563

Emergency starting engine

1. Remove the top cowling.

2. Remove the start-in-gear protection cable from the starter, if equipped.

4. Prepare the engine for starting. For further information, see page 39. Be sure the engine is in neutral and that the clip is attached to the engine shut-off switch. The main switch must be “ ” (on), if equipped.

5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up.

1. Start-in-gear protection cable

3. Remove the starter/flywheel cover after removing the bolt(s).

6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise.

7. Give a strong pull straight out to crank and start the engine. Repeat if necessary.

Page 87

EMU29672

Engine fails to operate

EMU35322

Emergency engine operation

If the battery voltage is low or in the unlikely event of an ignition system malfunction, the engine speed may become erratic or the engine may stop. In such a situation, follow the procedure below. Disconnect the yellow cord (emergency circuit) of the CDI unit. Run the engine at low speed and return to port. NOTICE: Follow this procedure only

in an emergency and just long enough to return to port for repairs.

[ECM00382]

Trouble Recovery

ately. NOTICE: Do not attempt to run the outboard motor until it has been completely inspected.

[ECM00402]

1. Yellow cord

EMU33502

Treatment of submerged motor

If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi-

Page 88

INDEX

Alcohol and drugs................................... 2

Alert indicator ....................................... 27

Alert system.......................................... 29

Anode(s), inspecting and replacing ...... 73

Anti-fouling paint .................................. 15

Avoid collisions....................................... 3

Battery .................................................. 37

Battery, checking (electric start

models)............................................... 73

Battery, connecting .............................. 74

Battery, disconnecting.......................... 74

Battery requirements............................ 13

Boat horsepower rating........................ 12

Boating safety......................................... 2

Boating safety publications .................... 3

Breaking in engine................................ 33

Carbon monoxide................................... 2

CE Marking.............................................5

Checks after engine warm up............... 44

Checks after starting engine................. 43

Checks before starting engine.............. 33

Choke knob .......................................... 24

Choke switch........................................ 21

Clamping the outboard motor .............. 32

Cleaning the outboard motor ............... 59

Components diagram........................... 17

Control functions, checking.................. 34

Cooling water ....................................... 43

Cowling lock lever ................................ 27

Cruising in salt water or other

conditions...........................................54

Dismounting the outboard motor ......... 55

EC Declaration of Conformity (DoC)....... 4

Electric shock ......................................... 1

Emergency engine operation................ 81

Emergency equipment..........................15

Emergency starting engine ................... 80

Emergency, temporary action in........... 78

Engine fails to operate.......................... 81

Engine oil .............................................. 35

Engine oil, changing .............................66

Engine oil, filling.................................... 33

Engine oil requirements........................ 14

Engine shut-off cord (lanyard) .......... 1, 34

Engine shut-off cord (lanyard) and

clip...................................................... 23

Engine stop button ............................... 23

Filling fuel..............................................37

First-time operation .............................. 33

Flushing device............................... 27, 35

Flushing in a test tank........................... 57

Flushing power unit .............................. 59

Fuel filter, checking............................... 66

Fuel leaks, checking for........................ 34

Fuel level...............................................34

Fuel requirements................................. 15

Fuel system........................................... 34

Fuel tank ............................................... 19

Fuel tank, cleaning................................72

Fuse, replacing ..................................... 78

Gasoline............................................1, 15

Gasoline exposure and spills.................. 2

Gear oil, changing................................. 70

Gear shift lever...................................... 21

Greasing ............................................... 64

Hot parts................................................. 1

Identification numbers record.................4

Idle speed, inspecting........................... 66

Impact damage.....................................78

Installation requirements ...................... 12

Instruments and indicators................... 28

Page 89

INDEX

Key number ............................................ 4

Laws and regulations.............................. 3

Low oil pressure alert ........................... 29

Low oil pressure-alert indicator............ 28

Lubrication............................................ 58

Main switch .......................................... 24

Maintenance chart 1............................. 61

Maintenance chart 2............................. 63

Manual starter handle........................... 24

Modifications .......................................... 2

Mounting height.................................... 31

Mounting outboard motor .................... 12

Mounting the outboard motor .............. 30

Neutral interlock trigger........................ 21

Neutral throttle lever............................. 21

Operating engine .................................. 38

Outboard motor, checking ................... 35

Outboard motor disposal

requirements ...................................... 15

Outboard motor (painted surface),

checking............................................. 60

Outboard motor safety ...........................1

Outboard motor serial number............... 4

Overloading ............................................ 2

Power tilt will not operate .....................79

Propeller ................................................. 1

Propeller, checking............................... 68

Propeller, installing ............................... 70

Propeller, removing............................... 69

Propeller selection................................13

Read manuals and labels ....................... 6

Rectifier Regulator (optional) ................ 13

Remote control box..............................20

Remote control lever ............................ 20

Remote control requirements ............... 12

Replacement parts ...............................60

Rotating parts .........................................1

Sending fuel (portable tank)..................38

Severe operating conditions................. 60

Shallow water ....................................... 52

Shifting.................................................. 44

Shifting (checks after engine warm

up)....................................................... 44

Spark plug, cleaning and adjusting ...... 65

Specifications ....................................... 10

Starter will not operate ......................... 79

Starting engine...................................... 39

Start-in-gear protection........................ 14

Steering friction adjuster....................... 25

Stop switches ....................................... 44

Stopping boat....................................... 46

Stopping engine ...................................46

Storing outboard motor ........................ 57

Submerged outboard motor................. 81

Passenger training.................................. 3

Passengers.............................................2

People in the water................................. 2

Periodic maintenance........................... 60

Personal flotation devices (PFDs)........... 2

Power tilt................................................. 1

Power tilt switch ................................... 24

Power tilt system, checking.................. 36

Power tilt unit........................................ 26

Throttle friction adjuster........................22

Throttle grip .......................................... 22

Throttle indicator................................... 22

Tiller handle ..........................................21

Tilt lock mechanism.............................. 26

Tilt support bar ..................................... 26

Tilt support knob................................... 26

Tilting up and down.............................. 50

Page 90

INDEX

Top cowling, installing.......................... 36

Top cowling, removing ......................... 34

Transporting and storing outboard

motor .................................................. 55

Trim rod (tilt pin).................................... 25

Trimming outboard motor..................... 47

Troubleshooting.................................... 75

Warming up engine ..............................44

Warning labels........................................ 6

Weather .................................................. 3

Wiring and connectors, inspecting....... 68

Page 91

Page 92

Printed in Japan December 2013–0.9 × 1 CR

Printed on recycled paper

Yamaha F9.9J, FT9.9L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important manual information

Table of contents

Safety information

General information

Specifications and requirements

Components

Instruments and indicators

Engine control system

Installation

Operation

Maintenance

Trouble Recovery

INDEX